JP2008126632A - Manufacturing method of foamed resin molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a foamed resin molded product capable of holding a subsidiary material to the inner surface of a mold by an easy and inexpensive technique and not lowering the characteristics of a fibrous material. <P>SOLUTION: Magnetic fibers 5 are laminated to the region facing a magnet 3 in a subsidiary material 4 by an adhesive or the like, and the subsidiary material 4 is held to the inner surface of an upper mold 1 in a close contact state by magnetically attracting the magnetic fibers 5 to the magnet 3. After a urethane raw liquid is supplied into a lower mold 2, the upper mold 1 having the subsidiary material 4 magnetically attracted on its inner surface is mounted on and clamped to the lower mold 2 to heat and foam urethane. After foaming, the mold is opened to demold the foamed resin molded product. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a foamed resin molded product applied to a method for molding a seat pad of an automobile, and more particularly to a method for manufacturing a foamed resin molded product in which a subsidiary material such as a resin foam or press felt is integrally molded. .

  As an automobile seat pad, there is one in which a subsidiary material such as chip-like urethane foam or press felt is integrated with a resin foam such as polyurethane foam.

  Japanese Patent Application Laid-Open No. 2001-170948 describes a foam molding method in which a chip made of urethane foam is integrally molded with a seat pad that is engaged with and held by a pin on the mold surface. ing.

  As a molding method for integrating a secondary material made of a fiber material with a resin foam, Japanese Patent Application Laid-Open No. 2001-252930 gives a magnet to a fiber material made of polyester fiber or acrylic fiber, and is provided in a mold. Describes a foam molding method in which a fiber material is held on the inner surface of a mold.

In the same publication, as a method of imparting magnetism to the fiber-based material, a method of mixing magnetic powder such as iron powder in the binder of the fiber-based material, or a layer of magnetic powder bonded and integrated with the fiber-based material and the layer And a method of replacing 10-30% of the fibers of the fiber-based material with metal fibers.
JP 2001-170948 A JP 2001-252930 A

  In a structure in which a urethane foam chip is engaged with a pin and held in a mold as in Japanese Patent Application Laid-Open No. 2001-170948, holding of the chip is unstable, and there is a possibility of dropping or moving.

  In the method of holding a secondary material on a mold by the magnetic force of Japanese Patent Laid-Open No. 2001-252930, there is a problem to be improved in the method of imparting magnetism to the secondary material.

  That is, among the above-mentioned magnetism imparting methods, the method of mixing magnetic powder into the binder of the fiber-based material imparts sufficient magnetism as long as the magnetic powder is mixed in the binder in a large amount and the amount of binder used is not significantly increased. However, if this is done, the flexibility of the fiber-based material may be impaired, and the magnetic powder may fall off the product.

  There is a similar problem in the method of bonding and integrating the magnetic powder layer with the fiber material.

  Even in the method of using magnetic fibers as part of the fibers of the fiber material, the flexibility of the fiber material may be impaired. In addition, blending or knitting synthetic resin fibers such as polyester fibers or acrylic fibers and metal fibers significantly increases the manufacturing cost of the fiber-based material. Moreover, when 10-30% of metal fibers having a large specific gravity are used, the weight of the fiber-based material is considerably increased. If the ratio of the metal fibers is reduced, the fiber material cannot be sufficiently magnetized, and it is difficult to hold the fiber material firmly on the inner surface of the mold.

  An object of the present invention is to solve the above-described conventional problems and to provide a method for producing a foamed resin molded product that can hold secondary materials firmly on the inner surface of a mold by an easy and inexpensive method. .

  The method for producing a foamed resin molded article of the present invention (Claim 1) is a foamed resin molded article in which the secondary material is integrated by holding the secondary material on the inner surface of the mold and foaming the foamed resin stock solution in the mold. A foamed resin molding in which magnetism is imparted to the secondary material, a magnetic body is installed in the mold, and the secondary material is held on the inner surface of the mold by the magnetic force of the magnetic body In the product manufacturing method, the secondary material is magnetized by attaching magnetic fibers to the secondary material.

  The method for producing a foamed resin molded article according to claim 2 is characterized in that, in claim 1, the foamed resin is a urethane foam resin.

  According to a third aspect of the present invention, there is provided a method for producing a foamed resin molded product according to the first or second aspect, wherein the magnetic fiber is a magnetic metal fiber.

  The method for producing a foamed resin molded article according to claim 4 is characterized in that, in any one of claims 1 to 3, a magnet is attached to the inner surface of the mold, and the magnetic fiber is magnetically attached to the magnet. To do.

  According to a fifth aspect of the present invention, there is provided a method for producing a foamed resin molded product according to the fourth aspect, wherein the magnetic fiber is attached to a region of the auxiliary material facing the magnet.

  According to a sixth aspect of the present invention, there is provided a method for producing a foamed resin molded product according to any one of the first to fifth aspects, wherein the auxiliary material is made of a resin foam or a press felt.

  In the present invention, magnetism is imparted to the secondary material by attaching magnetic fibers to the secondary material. Therefore, for example, by attaching a lot of magnetic fibers only in the vicinity of facing the magnetic body such as a magnet on the mold side, the weight of the secondary material is almost increased without affecting the characteristics of the secondary material as a whole. Without making it, it is possible to impart sufficient magnetism to hold the secondary material firmly in the mold.

  Further, since the magnetic fiber is attached to the existing secondary material, a popular product can be used as the secondary material itself, and the cost is low.

  Furthermore, even if the position of the magnetic body such as a magnet is different for each mold, the secondary material can be magnetically attached to the mold by sticking the magnetic fiber at a position corresponding to the magnetic body of the mold.

  In the present invention, since the magnetic fiber is pasted on the secondary material, the secondary material is sufficiently applicable even when the secondary material is made of urethane foam or press felt.

  In addition, although a magnet is suitable as a magnetic body, an electromagnet may be sufficient.

  Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a sectional view for explaining a mold used in the method for producing a foamed resin molded product according to the embodiment, and FIG. 2 is an enlarged sectional view of the vicinity of the magnet in FIG. Since this mold is symmetrical, only the left half is shown in FIG. The right half appears symmetrically with the left half.

  The mold for foam molding used in this embodiment is for molding an automobile seat pad, and includes an upper mold 1 and a lower mold 2. The upper mold 1 and the lower mold 2 are each made of a nonmagnetic metal material such as aluminum or an aluminum alloy.

  A plurality of magnets 3 are provided on the inner surface of the upper mold 1, that is, the cavity surface. In this embodiment, a recess is provided in the inner surface of the upper mold 1, and the magnet 3 is fitted in this recess. The magnet 3 is fixed to the upper mold 1 by a fixing method such as caulking, screwing, bolting, and adhesion. The surface of the magnet 3 is flush with the surrounding upper mold cavity surface.

The area facing the cavity surface of one magnet 3 is preferably about 1 to 2000 mm ² . It is sufficient that about 5 to 50 magnets 3 are arranged per 1 m ² , but it may be more or less than that.

  Moreover, it is preferable to arrange the magnet 3 at a predetermined interval in the edge direction so that the edge does not turn over on the cavity surface where the edge of the sheet-like auxiliary material 4 faces.

  In this embodiment, the auxiliary material 4 has a sheet shape, but may have a chip shape. The material of the auxiliary material 4 is preferably rigid urethane foam or press felt. A magnetic fiber 5 is attached to a region of the auxiliary material 4 facing the magnet 3 with an adhesive or an adhesive. The magnetic fiber 5 is preferably a woven fabric, non-woven fabric, or net-like shape because it is easy to handle and can be freely deformed following the surface shape of the auxiliary material 4, but a plurality of fibers are aligned in parallel. It may be.

  When the magnetic fiber 5 is magnetically attracted to the magnet 3, the auxiliary material 4 is held in close contact with the inner surface of the upper mold 1.

  In order to perform foam molding of the seat pad, after supplying the urethane stock solution into the lower mold 2, the upper mold 1 in which the auxiliary material 4 is magnetically attached to the inner surface as described above is attached to the lower mold 2 and the mold is used. Tighten and heat foam urethane.

  After foaming, the mold is opened and the molded product is removed. The auxiliary material 4 is integrated with the foam molded product, and is smoothly separated from the upper mold 1.

  In the cavity center portion 6 shown in FIG. 1, seat portions such as the lower part of the bottom and the lower thigh of the seat pad are formed, and in the cavity side portion 7, the side portion (bank portion) of the seat pad is formed. The auxiliary material 4 is arranged on the bottom surface of the molded seat pad.

  As said magnetic fiber 5, metal fibers, such as iron and nickel, are cheap and suitable, However, Magnetic yarn which knead | mixed the ferromagnetic metal oxide powder with the binder and shape | molded in the thread form may be sufficient. Alternatively, a magnetic yarn having a core-sheath structure in which a ferromagnetic powder is disposed in a hole of a synthetic resin hollow fiber may be used.

  The thickness of the magnetic fiber 5 should just be what can be affixed. However, about 100 to 3000 μm is usually preferable.

  The auxiliary material 4 is preferably a hard urethane foam chip-shaped product, a hard urethane foam slab (cut from a foam), a press felt, or the like. Examples of the fibers constituting the press felt include, but are not limited to, synthetic resin fibers such as polyester, acrylic, and polypropylene.

  The above embodiment is an example of the present invention, and the present invention may take forms other than those shown in the drawings. For example, the present invention can be applied to molding of a foam molded product other than a seat pad. The resin is not limited to urethane. The auxiliary material may be a rigid urethane foam or a fiber-based material other than press felt.

It is sectional drawing explaining the shaping | molding method which concerns on embodiment. It is an expanded sectional view of the magnet vicinity of FIG.

Explanation of symbols

1 Upper mold 2 Lower mold 3 Magnet 4 Secondary material 5 Magnetic yarn

Claims (6)

A method for producing a foamed resin molded product in which the subsidiary material is integrated by holding the subsidiary material on the inner surface of the mold and foaming the foamed resin stock solution in the mold,
In the method for producing a foamed resin molded article, in which magnetism is imparted to the auxiliary material, a magnetic body is installed in the mold, and the auxiliary material is held on the inner surface of the mold by the magnetic force of the magnetic body.
A method for producing a foamed resin molded product integrated with a secondary material, wherein the secondary material is magnetized by attaching magnetic fibers to the secondary material.   2. The method for producing a foamed resin molded product according to claim 1, wherein the foamed resin is a urethane foam resin.   3. The method for producing a foamed resin molded product according to claim 1, wherein the magnetic fiber is a magnetic metal fiber.   4. The method for producing a foamed resin molded article according to claim 1, wherein a magnet is attached to the inner surface of the mold, and the magnetic fiber is magnetically attached to the magnet.   5. The method for producing a foamed resin molded product according to claim 4, wherein the magnetic fiber is attached to a region of the auxiliary material facing the magnet.   The method for producing a foamed resin molded product according to any one of claims 1 to 5, wherein the auxiliary material is made of a resin foam or a press felt.

Images